EDITOR'S COMMENT
Casting users & foundries to stay together taking care of the industry
The industry in general and the foundry industry in particular went through rough weather on a road which was full of pits and ditched and bumps. All have experienced the discomforts while travelling a vehicl that went over such roads.
NEWS CORNER
Metaldyne Files for Bankruptcy, Looks to Sell Businesses
Motor vehicle industry supplier Metaldyne Corp., Plymouth, Mich., announced it has filed for Chapter 11 bankruptcy to address monetary needs and facilitate a restructuring, which will include the sale of the majority of its remaining assets.
Georg Fischer Divesting Casting Facility in Restructuring
Georg Fischer (GF), Schaffhausen, Switzerland, announced that its GF Automotive division will sell its light metals casting facility in Gleisdorf, Austria, to industrial holding company Bavaria Industriekapital, Munich, Germany, for an undisclosed amount.
TECHNOLOGY FOCUS
Practical Issues in Computer Simulation of Casting Processes
COMPUTER SIMULATIONS usually follow the procedure shown in Fig. 1. This section describes important elements and points of the simulations, namely, setting clear simulation objectives, selection of proper simulation code, hints in modeling of shape and phenomena, initial and boundary conditions, physical properties, enmeshing, and evaluation of simulation results, providing foundry process engineers some insights into the application of
models to real world problems.
SPECIAL COVERAGE
A Systematic Approach to the Development of Process Failure Modes and Effect Analysis for Casting Process
This paper attempts to explain the methodology for carrying out Failure Mode and Effect Analysis for a casting process although the approach could be adopted for any process for that matter. Although a generic procedure for FMEA is already available[1], there are a number of elements in the FMEA that are not properly understood in terms of their implication, by the foundry engineers. A systematic and thorough understanding of the various elements and their significance cannot be overemphasised if the potential of FMEA methodology is to be fully exploited. In view of the fact that many foundries are supplying castings to automotive OEM manufacturers, it has become essential that they improve the reliability of their processes for their survival in the competitive market. Also this practice of FMEA is mandated as a requirement by ISO/TS 16949:2002 Quality Management System.
TECHNOLOGY/PROCESS REVIEW
Chunky Graphite in Ductile Iron Castings - Theories and Examples
Chunky graphite is a very common problem in heavy section ductile iron castings. Presence of chunky graphite seems to be more of a problem in ferritic, high Si and austenitic ductile iron. It has a significant impact on the mechanical properties and should be avoided or controlled if possible. The phenomenon of chunky graphite has been subject of several research projects all around the world, but it is still not fully understood. In this paper some of the theories will be presented along with examples describing the problem and possible ways of reducing the problem.
Effect of Pressure on Mechanical Properties and Microstructure During the Solidification Processing of LM6 Alloy
Solidification of metals and alloys are promoted to attain superior properties under high pressure within a reusable die. Here, the molten metal is solidified under applied hydrostatic pressure. Such cast fabricated components can be readily used in service or after a minor post-fabrication treatment. Generally, the engineering components fabricated under high pressure are fine grained with excellent surface finish and have almost no porosity1,2. The mechanical properties of these parts are significantly improved over those of conventional castings. Cast components have yield strength improved by 10-50%, elongation and fatigue strength as much as by 50-80%. Such components also have superior-weld ability and heat-treat ability. In addition, the entire casting process may be carried out without any feeding system, runners, gates, etc., so the yield is quite high with almost no scrap for recycling. It is fabricated in a single action operation with lesser energy requirements.
Process Control Instrumentation Saves Cost by Simple Tips
Instruments have a vital role in all processes. In metallurgical applications, their importance is already established. Metallurgy is no longer an art, as it was once described. Controlling right from the specifications of the raw materials to the process parameters, a lowcost low-rejection-prone product may be easily produced. For cost-effective way of using process control and instrumentation, certain basic facts should be understood and then the refinement in the process technique may be applied. Energy saving is very important and this can be achieved by these techniques.
|
